Process for making a flexible multi-panel sterilization assembly

ABSTRACT

A continuous process for making a multi-panel sterilization assembly, the process including the steps of: providing a moving, continuous base web; providing a plurality of subassemblies; applying the subassemblies in position on the moving, continuous base web to define repeating portions that incorporate the subassemblies and alternating portions that lack such subassemblies; providing side tabs; applying the side tabs in position on the moving, continuous base web with respect to at least one edge of the portions that incorporate the subassemblies; attaching the subassemblies and the side tabs to the moving, continuous base web to form a continuous work-piece; and separating the continuous work-piece into individual multi-panel sterilization assemblies, each multi-panel sterilization assembly comprising a barrier panel, a fold protection panel and at least one side tab.

FIELD OF THE INVENTION

The present invention relates in general to a process for manufacturinga sterilization assembly.

BACKGROUND OF THE INVENTION

A variety of products such as gowns, sheets, drapes, instruments, etc.which are required during surgery or other aseptic procedures, are usedon a daily basis in the normal operation of hospitals, clinics and thelike. Where such products are not pre-packaged in a sterile state, it isnecessary for the hospital or clinic to sterilize them before use.Furthermore, where these products are not disposable, and are employedmore than once, it is necessary that they be cleaned and otherwiseprepared for subsequent use. Prior to such use, however, it is essentialthat such products be sterilized.

Due to the volume of materials involved, it is often necessary tosterilize and store these products for later use. Accordingly, there hasbeen developed a procedure where such products, after cleaning,laundering and the like, are wrapped in sterilization fabric and thensterilized and stored for subsequent use. Disposable sterilizationfabric is typically cut into predetermined rectangular shapes and soldas sterilization wraps.

Traditional wrapping of a sterilization tray or similar articles in aconventional disposable sterilization wrap often involves a large amountof redundant material as excess corners and overlapping plies aregathered, folded, and secured together at the top of the sterilizationtray. Conventional disposable sterilization wrap is a flat, featurelesssheet of material that may occasionally contain one or more additionallayers of material for strength or absorbency. For example, U.S. Pat.No. 5,635,134 to Bourne, et al. discloses a multi-ply sterilization wrapwhich is formed by joining one or more sheets of sterilization wrap(e.g., two separate sheets or one sheet folded over) together to formtwo similarly sized, superposed panels that allow convenient dualwrapping of an article. As another example, U.S. Patent ApplicationPublication No. 2001/0036519 by Robert T. Bayer discloses a two plysterilization wrap that is formed of a single sheet of sterilizationwrap material which is folded to form two similarly sized, superposedpanels that are attached to each other. As yet another example, U.S.Patent Application Publication No. 2005/0163654 by Stecklein, et al.discloses a sterilization wrap material that has a first main panel anda second panel that is smaller than the main panel. The second panel issuperposed and attached to the central portion of the main panel suchthat it is contained entirely within the main panel to reinforce themain panel and/or provide additional absorbency.

Generally speaking, in these and other examples, conventional disposablesterilization wraps are readily manufactured by very simple processesinvolving overlaying two sheets of material or folding a single piece ofmaterial to form two sheets and then attaching the sheets togetherforming a unitary wrap.

Large sheets of conventional disposable sterilization wrap incombination with standard fold techniques do provide an advantage duringunwrapping of an item after sterilization, particularly when thesterilization wrap is formed from a material that may stiffen or take aset during the sterilization process. For example, when sterilizationwrap composed of nonwoven material made from certain thermoplasticpolymers are used in an extended or enhanced steam or heat sterilizationprocess, the nonwoven material may set or “imprint” the shape of thewrapped article or tray. During unwrapping of the article or tray,imprinted creases, folds or other deformations must be overcome duringunfolding so the sterilization wrap can lay flat. If the sterilizationwrap does not lie flat, it is possible for unfolded sides of thesterilization wrap to fold back up over the sterilized article or traywhile other portions of the wrap are being unfolded. This wouldcompromise the sterility of the article. The large expanses of materialand the rectangular shape of the sheets in combination with standardfolding techniques generally keep the sterilization wrap from foldingback onto itself during unwrapping.

When these large sheets of conventional sterilization wrap are reducedin size, the reduction in material amplifies the problem of unfoldedsides of the sterilization wrap folding back up over the sterilizedarticle or tray while other portions of the wrap are being unfolded.Moreover, this problem can also be amplified by altering the geometry ofthe sheet of sterilization wrap so the sheet is no longer rectangular(e.g., in order to reduce the amount of material in the sheet). However,the use of large sheets of conventional disposable sterilization wrapwith standard fold techniques provides large expanses of overlappingmaterials and multiple folds which require using and manipulatingexcessive amounts of material during the wrapping and unwrappingprocess, adding difficulty that slows the wrapping and unwrappingprocess, and creating waste.

Accordingly, there is an unmet need for a process to make an easy to useassembly, package or system that reduces the amount of sterilizationfabric needed for the sterile processing of an instrument tray orarticle. There is also an unmet need for a process to make an easy touse assembly, package or system that reduces the amount of sterilizationfabric and simplifies the task of unwrapping a sterilized instrumenttray or article while reducing or avoiding the likelihood that thesterilization fabric will fold back onto itself during unwrapping. Theneed is particularly apparent for process to make an assembly, packageor system having multiple panels and other components that reduce theamount of sterilization fabric, that can be used in an extended orenhanced steam or heat sterilization process, and that simplifies thetask of unwrapping a sterilized instrument tray or article whilereducing or avoiding the likelihood that the sterilization fabric willfold back onto itself during unwrapping.

BRIEF SUMMARY OF THE INVENTION

The problems described above are addressed by the present inventionwhich encompasses a continuous process for making a multi-panelsterilization assembly.

The process involves providing a moving, continuous base web. Thecontinuous base web has a longitudinal centerline and at two opposededges generally parallel with the centerline.

A plurality of subassemblies is provided, each subassembly having atleast two opposed edges and a barrier component. The plurality ofsubassemblies may be provided by unwinding a roll of material andseparating the material into individual subassemblies. Alternatively, astack of individual subassemblies may be provided. In an aspect of theinvention, at least one reinforcement element may be included with eachsubassembly. For example, at least one reinforcement element may beregistered and attached with each subassembly. For another example, aportion of the each subassembly is folded over itself between the twoopposed edges to form at least one reinforcement element.

The subassemblies are positioned on the continuous base web so that theat least two opposed edges of each subassembly are aligned with the twoopposed edges of the continuous base web to define repeating portionsthat incorporate the subassemblies and alternating portions that lacksuch subassemblies. The repeating portions with subassemblies arebarrier panel portions and the alternating portions that lacksubassemblies are fold protection panel portions. As described in moredetail below, alignment of the subassembly and base web encompassesconfigurations in which an edge of a subassembly extends beyond an edgeof the base web in a generally parallel manner and/or configurations inwhich an edge of the base web extends beyond the edge of a subassemblyin a generally parallel manner.

The process includes the step of providing side tabs. These side tabsare registered in position on the moving, continuous base web withrespect to at least one edge of the portions that incorporate thesubassemblies. For example, the side tabs may be accelerated andregistered in position.

The subassemblies and the side tabs are attached to the continuous baseweb to form a continuous work-piece. This continuous work-piece has twoopposed edges and barrier panel portions coinciding with thesubassemblies and fold protection panel portions coinciding with theportions lacking subassemblies. The continuous work-piece has a firstsurface including the subassemblies and an opposed second surface. Thesubassemblies and/or side tabs may be attached to the continuous baseweb utilizing ultrasonic bonding techniques. Alternatively and/oradditionally, thermal bonding, adhesive bonding, stitching, mechanicalengagement or the like may be used to attach these components together.The subassemblies and/or side tabs may be attached to the continuousbase web in sequence. For example, the subassemblies may be bonded tothe moving continuous base web and then the side tabs may be bonded tobecome part of the continuous work-piece. Alternatively, thesubassemblies and side tabs may be bonded to the continuous base websimultaneously.

The individual side tabs may be attached to the first surface, thesecond surface, or to both the first and second surfaces. In an aspectof the invention, the step of providing side tabs may include providingside tabs having barrier panel attachment means. These barrier panelattachment means may be adhesive tape, double-sided adhesive tape,cleavable release tapes, layered release tapes, cohesive materials, hookcomponents of hook-and-loop fastening systems, mechanical fasteningcomponents including, but not limited to, snaps, clips, magnets,catches, slots and tabs, and combinations thereof.

The continuous work-piece is then separated into individual multi-panelsterilization assemblies with each multi-panel sterilization assemblyincluding a barrier panel, a fold protection panel and at least a sidetab.

According to an aspect of the invention, the process may include thestep of adding indicia to the barrier panel, the indicia identifying anupper boundary of a content receiving region of the barrier panel. Theindicia may be added to the subassembly before the subassembly isattached to the continuous base web. Alternatively and/or additionally,the indicia may be added to the barrier panel portion of the continuouswork-piece after the subassembly is attached to the continuouswork-piece. In yet another aspect, the indicia may be added to thebarrier panel of the multi-panel sterilization assembly.

The process of the present invention may further include the stepregistering at least one pull tab in position on the barrier panelportion of the moving, continuous base web and then attaching the pulltab. For example, the pull tab may be accelerated and registered inposition. The pull tab may be attached to the second surface or thefirst surface. It is contemplated that the pull tab may be attached toboth the first and second surfaces. According to the invention, the pulltab may desirably be bonded to the moving, continuous base web alongwith the subassemblies and the side tabs. Alternatively and/oradditionally, the process may involve the step of registering inposition and attaching at least one pull tab in position on the barrierpanel of an individual multi-panel sterilization assembly either beforeor after the individual assembly is separated from the continuouswork-piece.

According to aspects of the invention, portions of the edges of thecontinuous work-piece may be cut to create a shape prior to the step ofseparating the continuous work-piece into individual multi-panelsterilization assemblies. For example, portions of the continuouswork-piece may be cut out from the two opposed edges toward thelongitudinal centerline prior to the step of separating the continuouswork-piece into individual multi-panel sterilization assemblies.

The process of the present invention may further include the step ofcollating multi-panel sterilization assemblies into a stack and foldingthe stack. In an aspect of the invention, the multi-panel sterilizationassemblies include reinforcement elements and at least one pull tab andthe multi-panel sterilization assemblies are collated so that thebarrier panels are superposed in the stack and the reinforcementelements and pull tabs create a separation between adjoining multi-panelsterilization assemblies in the stack for a user to insert one or morefingers to grip one or more individual multi-panel sterilizationassemblies in the stack.

The present invention also encompasses a continuous process for making amulti-panel sterilization assembly utilizing a discrete base web insteadof a continuous base web. Such a process involves providing asubassembly that includes at least two opposed edges and a barrier panelcomponent spanning between the two opposed edges. The subassembly may beprovided by unwinding a roll of material and cutting the material intoindividual subassemblies. Alternatively, a stack of individualsubassemblies may be provided. In an aspect of the invention, at leastone reinforcement element may be included with each subassembly. Forexample, at least one reinforcement element may be registered inposition and attached to each subassembly.

The subassembly is registered in position on a discrete base web. Thisdiscrete base web has a leading end, a trailing end, and two opposededges generally perpendicular to the leading and trailing ends such thatthe at least two opposed edges of a subassembly are aligned, e.g. tocoincide and/or to be spaced-away in a generally parallel fashion, withthe two opposed edges of the base web to define a discrete work-pieceincluding a barrier panel portion incorporating the subassembly and afold protection panel portion lacking the subassembly. The work-piecehas a first surface including the subassembly and an opposed secondsurface. Desirably, the discrete work-piece is supported on a belt orconveyor or it may be supported on or integrated with a carrier web.

The process includes the step of providing one or more side tabs. Theseside tabs are registered in position with respect to at least one edgeof the barrier panel portion of the work-piece.

The subassembly and the side tab(s) are attached to the base web toprovide a multi-panel sterilization assembly including a barrier panel,a fold protection panel and at least one side tab. The subassemblyand/or side tabs may be attached to the base web utilizing ultrasonicbonding techniques. Alternatively and/or additionally, thermal bonding,adhesive bonding, stitching, mechanical engagement or the like may beused to attach these components together. The subassembly and/or sidetabs may be attached to the base web in sequence. For example, thesubassembly may be attached to the base web and then the side tabs maybe attached to the base web. Alternatively, the subassembly and sidetabs may be attached to the base web simultaneously.

The individual side tabs may be attached to the first surface, thesecond surface, or to both the first and second surfaces. In an aspectof the invention, the step of providing side tabs may include providingside tabs having barrier panel attachment means. These barrier panelattachment means may be adhesive tape, double-sided adhesive tape,cleavable release tapes, layered release tapes, cohesive materials, hookcomponents of hook-and-loop fastening systems, mechanical fasteningcomponents including, but not limited to, snaps, clips, magnets,catches, slots and tabs, and combinations thereof.

According to an aspect of the invention, the process may include thestep of adding indicia to the barrier panel, the indicia identifying anupper boundary of a content receiving region of the barrier panel. Theindicia may be added to the subassembly before the subassembly isattached to the base web. Alternatively and/or additionally, the indiciamay be added to the barrier panel portion of the discrete work-pieceafter the subassembly is attached to the work-piece. In yet anotheraspect, the indicia may be added to the barrier panel of the multi-panelsterilization assembly.

The process of the present invention may further include the step ofregistering at least one pull tab in position on the base web and thenattaching the pull tab. The pull tab may be attached to the secondsurface or the first surface. It is contemplated that the pull tab maybe attached to both the first and second surfaces. According to theinvention, the pull tab may be attached to the base web along with thesubassembly and the side tab(s). Alternatively and/or additionally, theprocess may involve the step registering at least one pull tab inposition on the barrier panel of a multi-panel sterilization assemblyand then attaching the pull tab.

According to aspects of the invention, portions of the edges of thework-piece may be cut to create a shape for the multi-panelsterilization assembly. For example, portions may be cut out from thetwo opposed edges (or other edges) of the work-piece. Alternativelyand/or additionally, portions may be cut from the multi-panelsterilization assembly to change its shape or trim material.

The process of the present invention may further include the step ofcollating multi-panel sterilization assemblies into a stack and foldingthe stack. In an aspect of the invention, the multi-panel sterilizationassemblies include reinforcement elements and at least one pull tab andthe multi-panel sterilization assemblies are collated so that thebarrier panels are superposed in the stack and the reinforcementelements and pull tabs create separations between adjoining multi-panelsterilization assemblies in the stack to provide gaps for a user toinsert one or more fingers to grip one or more individual multi-panelsterilization assemblies in the stack.

The present invention also encompasses a stack of multi-panelsterilization assemblies and a process of making the same. The stackincludes a plurality of multi-panel sterilization assemblies that eachincludes a barrier panel, a fold protection panel, a reinforcementelement and at least one pull tab. The stack is collated so that thebarrier panels are superposed in the stack, whereby the reinforcementelements and pull tabs create separations between adjoining multi-panelsterilization assemblies in the stack to provide gaps for a user toinsert one or more fingers to grip and separate one or more of themulti-panel sterilization assemblies from the stack.

Other objects, advantages and applications of the present disclosurewill be made clear by the following detailed description of a preferredembodiment of the disclosure and the accompanying drawings whereinreference numerals refer to like or equivalent structures.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of an exemplary process for making amulti-panel sterilization assembly.

FIG. 2 is a schematic illustration of an exemplary process for making amulti-panel sterilization assembly.

FIG. 3 is a perspective view illustrating a detail of an exemplaryprocess for making a multi-panel sterilization assembly.

FIG. 4A is a top plan view of an exemplary work-piece from an exemplaryprocess for making a multi-panel sterilization assembly.

FIG. 4B is a bottom plan view of an exemplary work-piece from anexemplary process for making a multi-panel sterilization assembly.

FIG. 5 is a bottom plan view illustrating a detail of an exemplarywork-piece from an exemplary process for making a multi-panelsterilization assembly.

FIG. 6A is a perspective view of an exemplary stack of multi-panelsterilization assemblies.

FIG. 6B is a side view illustrating a detail of an exemplary stack ofmulti-panel sterilization assemblies.

DEFINITIONS

As used herein, the term “disposable” refers to a product that is soinexpensive that it may economically be discarded after only a singleuse. Products that are “disposable” are typically intended for singleuse. The term “single-use” refers to a product that is intended to beused for only once and is not intended to be re-used, re-conditioned,restored or repaired after that use. These products offer advantages inclinical settings by reducing the potential for contamination orinfection. In addition, these products can enhance work flow since theyare not collected and assembled for reprocessing and reuse.

As used herein, the term “sterilization assembly” refers to a flexiblearticle composed of fabric(s) and/or flexible material(s) that iswrapped around, folded around or otherwise encloses a non-sterilearticle or non-sterile content prior to sterilization. A sterilizationassembly has multiple panels and/or sections providing specific physicalproperties, functional characteristics and/or structure that provideadvantages for wrapping or folding, handling, strength, sterilization,storage after sterilization, and/or unwrapping or unfolding.

As used herein, the terms “web” or “nonwoven web” refers to a coherentstructure of individual fibers or filaments which are interlaid, but notin an identifiable repeating manner. Nonwoven webs have been, in thepast, formed by a variety of processes known to those skilled in the artsuch as, for example, meltblowing, spunbonding and bonded carded webprocesses. The term “web” or “nonwoven web” encompasses laminatematerials including one or more webs as combinations of woven fabricsand nonwoven webs and/or combinations of nonwoven webs and films.

As used herein, the terms “spunbond web” or “spunbonded web” refer to aweb of small diameter fibers and/or filaments which are formed byextruding a molten thermoplastic material as filaments from a pluralityof fine, usually circular, capillaries in a spinnerette with thediameter of the extruded filaments then being rapidly reduced, forexample, by non-eductive or eductive fluid-drawing or other well-knownspunbonding mechanisms. The production of spunbonded nonwoven webs isillustrated in patents such as Appel, et al., U.S. Pat. No. 4,340,563;Dorschner et al., U.S. Pat. No. 3,692,618; Kinney, U.S. Pat. Nos.3,338,992 and 3,341,394; Levy, U.S. Pat. No. 3,276,944; Peterson, U.S.Pat. No. 3,502,538; Hartman, U.S. Pat. No. 3,502,763; Dobo et al., U.S.Pat. No. 3,542,615; and Harmon, Canadian Patent No. 803,714.

As used herein, the term “meltblown fibers” means fibers formed byextruding a molten thermoplastic material through a plurality of fine,usually circular, die capillaries as molten threads or filaments into ahigh-velocity gas (e.g. air) stream which attenuates the filaments ofmolten thermoplastic material to reduce their diameters, which may be tomicrofiber diameter. Thereafter, the meltblown fibers are carried by thehigh-velocity gas stream and are deposited on a collecting surface toform a web of randomly disbursed meltblown fibers. The meltblown processis well-known and is described in various patents and publications,including NRL Report 4364, “Manufacture of Super-Fine Organic Fibers” byV. A. Wendt, E. L. Boone, and C. D. Fluharty; NRL Report 5265, “AnImproved device for the Formation of Super-Fine Thermoplastic Fibers” byK. D. Lawrence, R. T. Lukas, and J. A. Young; and U.S. Pat. No.3,849,241, issued Nov. 19, 1974, to Buntin, et al.

As used herein, “ultrasonic bonding” means a process performed, forexample, by fusing layers or fibers, desirably thermoplastic layers orfibers, together by application of ultrasonic energy. One non-limitingexample of ultrasonic boding is bonding obtained by passing the fabricbetween a sonic horn and anvil roll as illustrated in U.S. Pat. No.4,374,888 to Bornslaeger, the entire contents of which is incorporatedherein by reference.

As used herein “thermal bonding” means fusing layers or fibers,desirably thermoplastic layers or fibers, together through the directapplication of heat. One form of thermal bonding is thermal “pointbonding” in which one or more layers of fabric are joined at a pluralityof discrete bond points. For example, thermal point bonding generallyinvolves passing a fabric or web of fibers to be bonded between a heatedroll assembly such as, for example, a heated calender roll and an anvilroll. Point bonding may also be accomplished using high pressures thatfuse layers or fibers together. The calender roll is usually patternedin some way so that the entire fabric is not attached across its entiresurface, and the anvil roll is usually smooth. As a result, variouspatterns for calender rolls have been developed for functional and/oraesthetic reasons. One example of a pattern has points and is the HansenPennings or “H&P” pattern with about a 30% bond area with about 200bonds/square inch (31 bonds/square cm) as taught in U.S. Pat. No.3,855,046 to Hansen and Pennings. Another example is shown in U.S.Design Pat. No. 239,566 to Vogt. Typically, the percent bonding areavaries from around 5% to around 30% of the area of the fabric laminateweb. Point bonding holds the laminate layers together as well as impartsintegrity to each individual layer by bonding filaments and/or fiberswithin each layer without destroying the breathability or hand of thefabric.

As used herein, the terms “align” and “alignment” refer to theadjustment of components so they are in proper relative position. Withrespect to subassembly edges and base web edges, these terms refer tothe adjustment of these components such that the edges generallycoincide. These terms also encompass configurations in which these edgesare “spaced-away” or “spaced-apart” or offset in a generally parallelfashion or in which these edges on one side of the longitudinalcenterline coincide and the opposite edges are spaced-away, spaced-apartor offset in a generally parallel fashion. One non-limiting example ofspaced-away edge alignment is when an edge of a subassembly extendsbeyond an edge of the base web; another non-limiting example is when anedge of the base web extends beyond the edge of a subassembly.

DETAILED DESCRIPTION

Reference will now be made in detail to one or more embodiments,examples of which are illustrated in the drawings. It should beunderstood that features illustrated or described as part of oneembodiment may be used with another embodiment to yield still a furtherembodiment.

Turning now to the drawings, there is shown at FIG. 1 an exemplaryprocess for making a multi-panel sterilization assembly. The exemplaryprocess may be configured for a continuous base web or a discrete baseweb. The process illustrated schematically by FIG. 1 shows a continuousbase web which may be unwound from a roll of material.

The process continues with material for a barrier component beingunwound from a roll. Optionally, material for reinforcement elements tobe located on the barrier component may also be unwound from a roll andcombined with the barrier component by attaching to form a laminatestructure. The barrier component, with or without the optionalreinforcement elements, may be separated, e.g. cut, to create discretesubassemblies. Alternatively, the subassemblies may be provided as astack instead of being unwound and separated. The subassemblies areregistered and placed on the base web. Side tabs, which may be combinedwith optional barrier panel attachment means, are registered and placedon the base web. These components (e.g., the subassemblies and the sidetabs) are attached to permanently to the base web. The components may beinitially secured in position on the moving web with use of a lightadhesive prior to being permanently attached, e.g. via thermal and/orultrasonic bonding. Alternatively, a heavy application of adhesive maybe used if attaching the components is to be achieved by adhesivebonding.

A pull tab is applied in position on the base web and then attached inplace. The pull tab may be applied along with the side tabs andsubassemblies and all the components may be attached simultaneously.

Edges of the base web incorporating these components may be trimmedbefore the continuous web is separated into individual multi-panelsterilization assemblies that are collated and stacked. The stack isdesirably packaged for shipment.

At locations of introductions of discrete components into the process,inspection can take place to determine the presence or absence ofacceptable component introduction. In addition to visual inspection,operational characteristics such as start-up/ramp-up/shut-downoperations can trigger waste minimization techniques. At each of theoperations or steps shown in FIG. 1, diagnostics can be performed toindicate whether contributions to the work-piece meet acceptablecriteria. If so, components such as the subassembly, side tabs,pull-tabs, etc., may continue to be applied as shown in FIG. 1. If not,no additional components are applied.

Referring now to FIG. 2, a process 10 for making a multi-panelsterilization assembly is shown schematically. While the invention willbe described in connection with desired or preferred embodiments, itwill be understood that it is not intended to limit the invention tothose embodiments.

According to the present invention, a continuous base web 12 is unwoundfrom a supply roll 14 and travels in the direction indicated by thearrow associated therewith as the supply roll 14 rotates in thedirection of the arrows associated therewith. The base web 12 may beformed by one or more sheet making processes and passed directly intothe process 10 without first being stored on a supply roll 14. Exemplarysheet-making processes include processes such as meltblowing processes,spunbonding processes, bonded-carded web-making processes, wet-layingprocesses, apertured film-forming processes, and the like. Thecontinuous base web 12 has a longitudinal centerline “L” and at twoopposed edges 12A and 12B generally parallel with the longitudinalcenterline L. It is contemplated that a discrete base web may be usedinstead of a continuous base web. The discrete base web may be supportedon a conveyor, a belt, a fabric or a carrier material such as acontinuous web of spunbond material. It is contemplated that the carriermaterial may become part of the finished product after processing.

The base web 12 passes through the nip 16 of an S-roll arrangement 18 ina reverse-S path. From the S-roll arrangement 18, the base web 12 passesto a combining drum 20 which is used to register and place a subassembly22 on the base web 12. Each subassembly 22 has at least two opposededges 22A and 22B and a barrier component. In an aspect of theinvention, at least one reinforcement element 40 may be included witheach subassembly 22.

Generally speaking, the subassembly 22 is formed by unwinding a barriercomponent material 24 from a supply roll 26 and travels in the directionindicated by the arrow associated therewith as the supply roll 26rotates in the direction of the arrows associated therewith. Thesubassembly may include optional reinforcement elements. One way toinclude the reinforcement elements is to unwind one or more rolls ofreinforcement element material 28 from a supply roll 30 that travels inthe direction indicated by the arrow associated therewith and positionthe reinforcement element material 28 against the barrier componentmaterial 24 by passing both materials 28, 24 through nip arrangement 32.Another way to include the reinforcement elements is to fold a portionor portions of barrier component material 24 in the direction of travelindicated by the arrow associated with the supply roll 26 via a foldingboard (not shown) that is positioned between the supply roll 26 and thecombining drum 20. The barrier component material and/or thereinforcement element material may be formed by one or more sheet makingprocesses and passed directly into the process 10 without first beingstored on a supply roll. Exemplary sheet-making processes includeprocesses such as meltblowing processes, spunbonding processes,bonded-carded web-making processes, wet-laying processes, aperturedfilm-forming processes, and the like.

Referring to FIGS. 2 and 3, the barrier component material 24 andreinforcement element material 28 travels to a nip of a bonding rollarrangement 32 where the materials are attached together. The materialsmay be attached using conventional techniques. Examples of techniquesinclude, but are not limited to, ultrasonic bonding, thermal bonding,pressure bonding, hot melt adhesives, double-sided tape, transferadhesives or the like. These combined materials 34 travel to a rotaryknife cutting roll 36 arrangement where an individual subassembly 22 iscut and then placed on a combining drum 20. Other techniques may be usedto separate the subassembly. Exemplary techniques include a rotary die,lasers, water jets or the like.

The combining drum 20 holds the subassembly 22 on the drum surface usingconventional techniques such as, for example, suction. Other techniquesmay be used to register the subassembly in position and transfer it tothe base web. These include transfer pucks, belt placement assemblies orthe like. Non-limiting examples of suitable apparatus and methodsinclude those described in U.S. Pat. Nos. 5,716,478 and 5,759,340, bothto Boothe et al., the contents of which are incorporated herein byreference. Alternatively, a stack of individual subassemblies 22 may beprovided and the individual subassemblies may be fed to the combiningdrum (or other registration and transfer equipment using conventionaltechniques).

The subassembly 22 is transferred to the continuous web 12 in a transferstep. The surface of subassembly 22 that is to face the continuous webor a portion of the continuous web 12 that is to receive the subassembly22 may include a light coating of an adhesive (not shown) to maintainthe subassembly in position on the continuous web 12.

According to the present invention, the base web 12 and/or thesubassembly 22 may be composed of at least one layer of a breathablenonwoven material. Desirably, the breathable nonwoven material is alaminate composed of a layer of spunbonded filaments, a layer ofmeltblown fibers, and a layer of spunbonded filaments—also calledspunbonded-meltblown-spunbonded material. The method of making theselayers is known and described in commonly assigned U.S. Pat. No.4,041,203 to Brock et al which is incorporated herein in its entirety byreference. The material of Brock et al is a three layer laminate ofspunbonded-meltblown-spunbonded layers which is also commonly referredto by the acronym “SMS”. The two outer layers of SMS are a spunbondedmaterial made from extruded polyolefin fibers, or filaments, laid downin a random pattern and then attached to one another. The inner layer isa meltblown layer also made from extruded polyolefin fibers generally ofa smaller diameter than the fibers in the spunbonded layers. As aresult, the meltblown layer provides increased barrier properties due toit fine fiber structure which permits the sterilizing agent to passthrough the fabric while preventing passage of bacteria and othercontaminants. Conversely, the two outer spunbonded layers provide agreater portion of the strength factor in the overall laminate. Thelaminate may be prepared using an intermittent bond pattern that ispreferably employed with the pattern being substantially regularlyrepeating over the surface of the laminate. The pattern is selected suchthat the bonds may occupy about 5-50% of the surface area of thelaminate. Desirably, the bonds may occupy about 10-30% of the surfacearea of the laminate. Other combinations and variations of thesematerials are contemplated. As a non-limiting example, the inner layermay contain two meltblown layers such that the material may be called“SMMS”.

When the base web 12 and/or the subassembly 22 is composed of orincorporates SMS material(s), the basis weight of the SMS material(s)may be from 1 ounce per square yard or “osy” which is approximately (33grams per square meter or “gsm”) to about 3 osy (100 gsm). For example,the basis weight of the SMS material(s) may be from 1.2 osy (40 gsm) toabout 2 osy (67 gsm). As another example, the basis weight of the SMSmaterial(s) may be from 1.4 osy (47 gsm) to about 1.8 osy (60 gsm). Thebasis weight may be determined in accordance with ASTM D3776-07.Multiple plies or layers of SMS material may be used to provide basisweights ranging from about 2 osy (67 gsm) to about 5 osy (167 gsm).

The permeability of the base web and/or the subassembly (or the combinedcomponents as a barrier panel portion described hereinafter as barrierpanel portion 42) may range from 25 to about 500 cubic feet per minute(CFM) as characterized in terms of Frazier permeability. For example,the permeability of the barrier panel portion may range from 50 to about400 cubic feet per minute. As yet another example, the permeability ofthe barrier panel portion may range from 100 to about 300 cubic feet perminute. The Frazier permeability, which expresses the permeability of amaterial in terms of cubic feet per minute of air through a square footof area of a surface of the material at a pressure drop of 0.5 inch ofwater (or 125 Pa), was determined utilizing a Frazier Air PermeabilityTester available from the Frazier Precision Instrument Company andmeasured in accordance with Federal Test Method 5450, Standard No. 191A.When the barrier panel is composed of or incorporates SMS material(s)having basis weights ranging from about 1 osy (33 gsm) to about 2.6 osy(87 gsm), the permeability of the barrier panel portion may range fromabout 20 cubic feet per minute to about 75 cubic feet per minute whendetermined generally in accordance with ISO 9237:1995 (measured with anautomated air permeability machine using a 38 cm² circular test area(e.g., test head) at a test pressure of 125 Pa,—exemplary airpermeability machine is TEXTEST FX 3300 available from TEXTEST AG,Switzerland). If multiple plies or layers of SMS material are used toprovide basis weights ranging from about 2 osy (67 gsm) to about 5 osy(167 gsm), the permeability of the barrier panel may range from about 10cubic feet per minute to about 30 cubic feet per minute when determinedgenerally in accordance with ISO 9237:1995.

Generally speaking, the material of the base web 12 and the barriercomponent material 24 of the subassembly 22 may be of the same materialor they may be different materials. For example, the base web 12 may besingle layer or multiple layers of spunbond nonwoven material, alightweight nonwoven laminate material, or a material that lacks thelevel of barrier properties (or other characteristics) that may bedesired for the barrier panel portion. Alternatively, the base web maybe an “SMS” material. The barrier component material 24 may have ahigher level of barrier properties than the base web 12. Alternatively,it is contemplated that the base web 12 may have a higher level ofbarrier properties than the barrier component material 24. For example,the base web 12 may be a laminate of nonwoven fabrics such as “SMS”material. The base web 12 may have a different color and/or pattern thanthe barrier component material 24; as a non-limiting example, the baselayer 12 may have a first color (e.g., a blue color), a dark color, or aspecific color on a color scale and the subassembly (or the barriercomponent of the subassembly) may have no color (e.g., white), a secondcolor (e.g., a light color), or a specific color on a color scale thatcontrasts with the first color.

As illustrated in FIG. 3, the subassemblies 22 are applied in positionon the continuous base web 12 so that the at least two opposed edges 22Aand 22B of a subassembly are aligned with the two opposed edges 12A and12B of the continuous base web 12 to define repeating portions 42 thatincorporate the subassemblies (also referred to as barrier panelportions 42) and alternating portions 44 that lack such subassemblies(also referred to as fold protection panel portions 44).

The process includes the step of providing one or more side tabs 46.These side tabs 46 are registered in position on the moving, continuousbase web 12 with respect to at least one edge of the portions 42 thatincorporate the subassemblies 22. For example, the side tabs may beaccelerated and registered in position. Generally speaking, the sidetabs 46 are formed by unwinding a material 48 from a supply roll 50which travels in the direction indicated by the arrow associatedtherewith as the supply roll 50 rotates in the direction of the arrowsassociated therewith. The side tabs 46 may include optional barrierpanel attachment means that may be applied to the side tabs 46 beforethe side tabs are applied to the continuous web 12. The material 48 maybe separated in a cutting operation 52 to form the side tab s 46 andtransferred to a combining roll 54 or other operation to register andplace the side tab(s) onto the continuous web 12. The combining roll 54holds the side tabs 46 on the drum surface using conventional techniquessuch as, for example, suction. Other techniques may be used to registerthe side tabs in position and transfer it to the base web. These includetransfer pucks, belt placement assemblies or the like. Alternatively, astack of individual side tabs 46 may be provided and the individual sidetabs 46 may be fed to the combining roll (or other registration andtransfer equipment using conventional techniques. The side tab 46 or aportion of the continuous web 12 that is to receive the side tab 46 mayinclude a light coating of an adhesive (not shown) to maintain thesubassembly in position on the continuous web 12.

Alternatively and/or additionally, the barrier panel attachment meansmay be applied to the barrier panel portion (not shown in the Figures).

These barrier panel attachment means may be adhesive tape, double-sidedadhesive tape, cleavable release tapes, layered release tapes, cohesivematerials, hook components of hook-and-loop fastening systems,mechanical fastening components including, but not limited to, snaps,clips, magnets, catches, slots and tabs, and combinations thereof. Forexample, the panel attachment means may be one or more lengths ofadhesive tape having at least an end or portion that is stitched,ultrasonically bonded, thermo-mechanically bonded or adhered oradhesively bonded to the barrier panel or the side tab. It has beenfound that barrier panel attachment means may be a double sided tapehaving the same or different levels of adhesive or tack strength ofadhesive on each side. Alternatively and/or additionally, the panelattachment means may have a double sided tape structure in which thecentral layer sandwiched by the adhesive is a splittable or separablematerial such as a splittable paper, splittable laminate, splittablefoam, cleavable paper, cleavable release structure, cleavable foam orother cleavable or separable laminate. Exemplary splittable or cleavablematerials are disclosed at, for example, U.S. Pat. No. 5,702,555 issuedto Caudal et al. on Dec. 30, 1997; U.S. Pat. No. 4,310,127 issued toFrye on Jan. 12, 1982; U.S. Pat. No. 3,675,844 issued to Sorrell on Jul.11, 1972; and U.S. Pat. No. 2,205,956 issued to Humphner on Jun. 25,1940; the contents of which are incorporated by reference. According toan aspect of the invention, the panel attachment means may be in theform of an adhesive fastening tab or tape closure system such as thevarious types frequently used on diapers, incontinent garments andsimilar products. An exemplary tape closure system may be found at, forexample, U.S. Pat. No. 4,410,325 issued to Lare on Oct. 18, 1983; thecontents of which are incorporated by reference. Another exemplary tapeclosure system may be found at, for example, U.S. Pat. No. 4,585,450issued to Rosch et al. on Apr. 29, 1986; the contents of which areincorporated by reference. As another example, the panel attachmentmeans may be a length of fabric such as nonwoven fabric having an end orportion that is stitched, ultrasonically bonded, thermo-mechanicallybonded or adhered or adhesively bonded to the barrier panel and/or theside tab and having a hook fastener from a hook and loop fasteningsystem joined to the other end. It is contemplated that the base weband/or the barrier panel portion itself may function as the loopcomponent of a hook and loop fastening system such as hook and loopfastenings systems available as VELCRO® brand fastener products fromVelcro Industries B. V. Other exemplary hook systems may be used such asthe hook system described in U.S. Pat. No. 5,315,740 issued to Nestegardwhich relates to hooks having small dimensions so they engage low costloop materials such as nonwoven webs. It is contemplated that variouselements or components of the panel attachment means, may be integrallyformed, such as by molding, co-extrusion or the like, along with anyassociated substrate layer. For example, the individual hook elementsmay be integrally formed simultaneously with a hook base-layer bycoextruding the base layer and hook elements from substantially the samepolymer material.

The subassemblies 22 and the side tabs 46 enter bonding station 55 wherethey are permanently attached to the continuous base web 12 to form acontinuous work-piece 56. With respect to at least the subassemblies 22,the subassemblies 22 are desirably joined at or adjacent the edges 12Aand 12B of the base web 12. The attachment may be a complete seam or theattachment may be partial along only one or a few portions of the edges.Alternatively and/or additionally, the attachment may be intermittent ordiscontinuous along all or a portion of each respective edge. Of course,other edges may also be attached or the layers may be attached togetheracross all or portions of their entire surface area. The side tabs 46are desirably attached in similar manners.

Referring to FIGS. 3, 4A, 4B and 5, this continuous work-piece 56 hastwo opposed edges 56A and 56B and barrier panel portions 42 coincidingwith the subassemblies 22 and fold protection panel portions 44coinciding with the portions lacking subassemblies. The continuouswork-piece 56 has a first surface 58 including the subassemblies 22 andan opposed second surface 60. The subassemblies 22 and/or side tabs 46may be attached to the continuous base web utilizing ultrasonic bondingtechniques. Alternatively and/or additionally, thermal bonding, adhesivebonding, stitching, mechanical engagement or the like may be used toattach these components together. The subassemblies and/or side tabs maybe attached to the continuous base web in sequence. For example, thesubassemblies may be attached to the moving continuous base web and thenthe side tabs may be attached to the moving continuous base web.Alternatively, the subassemblies and side tabs may be attached to thecontinuous base web simultaneously. The individual side tabs 46 may beattached to the first surface 58, the second surface 60, or to both thefirst and second surfaces 58 and 60. In an aspect of the invention, thestep of providing side tabs may include providing side tabs havingbarrier panel attachment means.

According to an aspect of the invention, the process 10 may include thestep of adding indicia 62 to the barrier panel, the indicia identifyingan upper boundary of a content receiving region of the barrier panel. Anon-limiting example of indicia 62 placement is shown in FIG. 4A. Theindicia 62 may be added to the subassembly 22 before the subassembly 22is attached to the continuous base web 12. Alternatively and/oradditionally, the indicia 62 may be added to the barrier panel portion42 of the continuous work-piece 56 after the subassembly is attached tothe continuous work-piece. In yet another aspect, the indicia may beadded to the barrier panel of the multi-panel sterilization assembly.The indicia may be in a variety of forms include lines, broken lines,imprinted bonding patterns, logos and other printed matter. Thus theindicia could be wording such as “KIMBERLY-CLARK” or “KIMGUARD®” or“SMARTFOLD®”.

The process of the present invention may further include the stepregistering at least one pull tab 64 in position on the barrier panelportion 42 of the moving, continuous base web 12 or the work-piece 56,and then attaching the pull tab 64. For example, the pull tab 64 may beaccelerated and registered in position. Generally speaking, the pulltabs 64 are formed by unwinding a material 64B from a supply roll 64Cwhich travels in the direction indicated by the arrow associatedtherewith as the supply roll 64C rotates in the direction of the arrowsassociated therewith. The material 64B may be separated in a cuttingroll arrangement 64D and transferred to a combining roll 64E or otheroperation to register and place the pull tab(s) 64 onto the continuousweb 12 or the work-piece 56. The combining roll 64E holds the pull tabs64 on the drum surface using conventional techniques such as, forexample, suction. Other techniques may be used to register the pull tabsin position and transfer it to the base web. Alternatively, a stack ofindividual pull tabs 64 may be provided and the individual pull tabs 64may be fed to the combining roll 64E (or other registration and transferequipment) using conventional techniques. The pull tab 64 or a portionof the continuous web 12 or the work-piece 56 that is to receive thepull tab 64 may include a light coating of an adhesive (not shown) tomaintain the pull tab 64 in position on the continuous web 12 or thework-piece 56.

The pull tab 64 may be attached to the second surface 60 or the firstsurface 58. It is contemplated that the pull tab may be attached to boththe first and second surfaces. According to the invention, the pull tabmay desirably be attached to the moving, continuous base web along withthe subassemblies and the side tabs. Alternatively and/or additionally,the process may involve the step of registering in position andattaching at least one pull tab in position on the barrier panel of anindividual multi-panel sterilization assembly either before or after theindividual assembly is separated from the continuous work-piece.

As shown in FIG. 5, portions of the edges 56A and 56B of the continuouswork-piece 56 may be cut to create a shape prior to the step ofseparating the continuous work-piece 56 into individual multi-panelsterilization assemblies. For example, portions of the continuouswork-piece 56 may be cut out from the two opposed edges 56A and 56Btoward the longitudinal centerline L prior to the step of separating thecontinuous work-piece into individual multi-panel sterilizationassemblies. The portions may be cut utilizing a rotary knife or othertechniques, including but not limited to, a rotary die, lasers, waterjets or the like.

The continuous work-piece 56 is then separated via a conventionalcutting operation 66 into individual multi-panel sterilizationassemblies 68, each multi-panel sterilization assembly including abarrier panel, a fold protection panel, and at least one side tab. Eachmay further include indicia and one or more pull tabs as well as otherfeatures. Of course, it is contemplated that one or more features suchas side tabs, indicia and/or pull tabs may be omitted.

The process of the present invention may further include the step ofcollating multi-panel sterilization assemblies into a stack and foldingthe stack. In an aspect of the invention, the multi-panel sterilizationassemblies include reinforcement elements and at least one pull tab andthe multi-panel sterilization assemblies are collated so that thebarrier panels are superposed in the stack. Referring to FIGS. 6A and6B, there is shown in side perspective view (FIG. 6A) and in sidecross-section view (FIG. 6B), not necessarily to scale, a stack 70 ofmulti-panel sterilization assemblies 68 collated so the barrier panels(i.e., barrier panel portions 42) are superposed. As can be seen, thereinforcement elements 40 and pull tabs 64 create a separation betweenadjoining multi-panel sterilization assemblies 68 in the stack 70 for auser to insert one or more fingers to grip one or more individualmulti-panel sterilization assemblies 68 in the stack 70.

The present invention encompasses a process for making a stack ofmulti-panel sterilization assemblies. That is, the above-describedprocess may be used to produce a collated stack of multi-panelsterilization assemblies including include reinforcement elements and atleast one pull tab such that the reinforcement elements 40 and pull tabs64 are arranged to create a separation between adjoining multi-panelsterilization assemblies 68 in the stack 70 for a user to insert one ormore fingers to grip one or more individual multi-panel sterilizationassemblies 68 in the stack 70.

While various patents have been incorporated herein by reference, to theextent there is any inconsistency between incorporated material and thatof the written specification, the written specification shall control.In addition, while the disclosure has been described in detail withrespect to specific embodiments thereof, it will be apparent to thoseskilled in the art that various alterations, modifications and otherchanges may be made to the disclosure without departing from the spiritand scope of the present disclosure. It is therefore intended that theclaims cover all such modifications, alterations and other changesencompassed by the appended claims.

What is claimed is:
 1. A continuous process for making a multi-panelsterilization assembly, the process comprising the steps of: providing amoving, continuous base web having a longitudinal centerline and twoopposed edges generally parallel with the centerline; providing aplurality of subassemblies, each subassembly comprising at least twoopposed edges and a barrier component that spans between the at leasttwo opposed edges; applying the subassemblies in position on the moving,continuous base web such that the at least two opposed edges of eachsubassembly are aligned with the two opposed edges of the continuousbase web to define repeating portions that incorporate the subassembliesand alternating portions that lack such subassemblies; providing sidetabs; applying the side tabs in position on the moving, continuous baseweb with respect to at least one edge of the portions that incorporatethe subassemblies; attaching the subassemblies and the side tabs to themoving, continuous base web to form a continuous work-piece having twoopposed edges, a longitudinal centerline, barrier panel portionscoinciding with the subassemblies, and fold protection panel portionscoinciding with the portions lacking assemblies, the continuouswork-piece having a first surface including the subassemblies and anopposed second surface; and separating the continuous work-piece intoindividual multi-panel sterilization assemblies, each multi-panelsterilization assembly comprising a barrier panel, a fold protectionpanel and at least one side tab.
 2. The process of claim 1 wherein theplurality of subassemblies are provided by unwinding a roll of materialand cutting the material into individual subassemblies.
 3. The processof claim 2, wherein at least one reinforcement element is included witheach of the subassemblies.
 4. The process of claim 1, whereinsubassemblies and/or side tabs are attached to the continuous base webutilizing ultrasonic bonding techniques.
 5. The process of claim 1,wherein subassemblies and/or side tabs are adhesively secured to thecontinuous base web prior to ultrasonic bonding.
 6. The process of claim1, further comprising the step of adding indicia to a subassembly beforethe subassembly is attached to the continuous base web, the indiciaidentifying an upper boundary of a content receiving region of eachbarrier panel.
 7. The process of claim 1, further comprising the step ofadding indicia to a barrier panel portion of the continuous work-pieceafter the subassembly is attached to the continuous work-piece, theindicia identifying an upper boundary of a content receiving region ofeach barrier panel.
 8. The process of claim 1, wherein the side tabs areattached to the first surface and/or the second surface.
 9. The processof claim 1, wherein at least one side tab that is attached to eachbarrier panel portion includes a barrier panel attachment means.
 10. Theprocess of claim 1, further comprising the step of applying at least onepull tab in position on the barrier panel portion of the moving,continuous base web and attaching the pull tab.
 11. The process of claim10, wherein the pull tab is attached to the moving, continuous base webalong with the subassemblies and the side tabs.
 12. The process of claim1, further comprising the step of applying at least one pull tab inposition on the barrier panel of an individual multi-panel sterilizationassembly after the individual assembly is separated from the continuouswork-piece and attaching the pull tab.
 13. The process of claim 1,wherein portions of the continuous work-piece are cut out from the twoopposed edges toward the longitudinal centerline prior to the step ofseparating the continuous work-piece into individual multi-panelsterilization assemblies.
 14. The process of claim 1, further comprisingthe step of collating multi-panel sterilization assemblies into a stackand folding the stack.
 15. The process of claim 14, wherein eachmulti-panel sterilization assembly includes at least one reinforcementelement and at least one pull tab and the multi-panel sterilizationassemblies are superposed in the stack, whereby the reinforcementelements and pull tabs create a separation between adjoining multi-panelsterilization assemblies in the stack for a user to insert one or morefingers to grip an individual multi-panel sterilization assembly in thestack.
 16. A continuous process for making a multi-panel sterilizationassembly, the process comprising the steps of: providing a subassemblycomprising at least two opposed edges and a barrier component spanningbetween the two opposed edges; applying the subassembly in position on adiscrete base web having a leading edge, a trailing edge, and twoopposed edges generally perpendicular to the leading edge and trailingedge such that the at least two opposed edges of a subassembly arealigned with the two opposed edges of the base web to define a discretework-piece comprising a barrier panel portion incorporating thesubassembly and a fold protection panel portion lacking the subassembly,the work-piece having a first surface including the subassembly and anopposed second surface; providing at least one side tab; and applyingthe at least one side tab in position on the work-piece with respect toat least one edge of the barrier panel portion; and attaching thesubassembly and the at least one side tab to the base web to provide amulti-panel sterilization assembly comprising a barrier panel, a foldprotection panel and at least one side tab.
 17. The process of claim 16,wherein at least one reinforcement element is included with thesubassembly.
 18. The process of claim 16, further comprising the step ofapplying at least one reinforcement element in position on the barrierpanel of the multi-panel sterilization assembly and attaching thereinforcement element to the multi-panel sterilization assembly.
 19. Theprocess of claim 16, further comprising the step of adding indicia tothe subassembly before the subassembly is registered in position on thebase web, the indicia identifying an upper boundary of a contentreceiving region of the barrier panel of the multi-panel sterilizationassembly.
 20. The process of claim 16, further comprising the step ofadding indicia to the barrier panel of the multi-panel sterilizationassembly, the indicia identifying an upper boundary of a contentreceiving region of the barrier panel.
 21. The process of claim 16,wherein the at least one side tab is attached to the first surfaceand/or the second surface.
 22. The process of claim 16, wherein the atleast one side tab includes a barrier panel attachment means.
 23. Theprocess of claim 16, wherein subassembly and/or the at least one sidetab are adhesively secured to the discrete base web prior to attaching.24. The process of claim 16, further comprising the step of cutting andremoving portions from one or more edges of the work-piece or themulti-panel sterilization assembly to create additional edges in themulti-panel sterilization assembly.
 25. The process of claim 16 whereinportions of the multi-panel sterilization assembly are cut to createadditional edges in the multi-panel sterilization assembly.
 26. Theprocess of claim 16, further comprising the step of collatingmulti-panel sterilization assemblies into a stack and folding the stack.27. The process of claim 26, wherein the multi-panel sterilizationassemblies include reinforcement elements and at least one pull tab andthe multi-panel sterilization assemblies are collated so that thebarrier panels are superposed in the stack, whereby the reinforcementelements and pull tab create a separation between adjoining multi-panelsterilization assemblies in the stack to provide a gap for a user toinsert one or more fingers to grip one or more individual multi-panelsterilization assemblies within the stack.